Sport cap and method for its production

ABSTRACT

A sport cap has a visor made of thick-walled neoprene foam rubber. The pattern of the visor is approximately crescent-shaped and has an arched inner edge, which is sewn in a stretched form to the elastic headband. In a use position, the visor has a middle convex curvature section and two lateral adjacent concave curvature sections, whereby there is a uniform transition between each of the curvature sections. Due to this multiple curvature of the visor, the visor has a form stability when in use but is at the same time soft and pliable. The cap with visor can be transported while crushed together in any form desired. The visor will always return to its original form once the cap is placed on the head.

FIELD OF THE INVENTION

[0001] The present invention relates, in general, to caps, and in particular, to a new and useful sport cap made up of several textile segments which have been sewn together, a head-band which is partly or all elastic and has a loose upper edge and a lower edge as well as a visor where an inner edge of the visor is sewn between an edge of the cap and the lower edge of the head-band.

[0002] Sport caps of this type are known as so-called visor caps. The visor is made of a stiff material which may be synthetic. There are also visors made of cardboard which are then covered with cap material. If the visor of well-known sport caps is to have a good form stability, the stiffness is so great that it has only limited pliability. In a situation of impact stress, the visor will bend or even break. In sport games involving balls these types of caps can even cause head injuries.

[0003] The inventor of the present invention is also the inventor of the sport cap disclosed and claimed in U.S. Pat. No. 5,754,983 which is incorporated herein by reference. U.S. Pat. No. 5,715,540 is relevant for disclosing a cap with elastic band.

SUMMARY OF THE INVENTION

[0004] It is a task of the present invention to provide a cap which has a good form stability when in use, i.e., when positioned on the head, but which can be folded tightly together in the smallest size possible without any damaging effects to the visor once the cap is unfolded and used the next time. Another task is to provide such a cap with a band that is at least partly elastic for adjustment to various sizes without the need for separate adjusting bands that are usually at the back of a sport cap.

[0005] These tasks have been solved in that the sport cap comprises a crown with a lower edge, an elastic head-band which has an upper edge that may be loose or not, and a lower edge, and a visor made of an elastic deformable, e.g., foam material as used in U.S. Pat. No. 5,754,983 (e.g. neoprene). The visor has an inner edge having a pair of opposite ends which are substantially aligned with each other when the visor is in a flat position. The visor is attached to the lower cap edge and the bottom or lower edge of the elastic head-band by aligning the visor with a front portion of the cap; stretching apart the opposite ends of the inner edge of the visor in opposite directions so that the initially curved inner edge is substantially straight; and attaching the now substantially straight inner edge to the lower cap edge and the bottom edge of the elastic head-band, during which the elastic head-band is maintained in a substantially tension-free state, or the straightened edge of the visor can be attached to the unstretched band first, and then the two can be attached to the crown.

[0006] An especially advantageous characteristic of this invention lies in the fact that when seen from the front, with the head-band straightened out, the visor forms, top-side, a middle convex curvature section and two laterally joining concave curvature sections. The convex curvature section preferentially converges uniformly into the concave curvature section. In use, therefore, the visor looks well formed and rigid, but is actually soft.

[0007] The visor is cut out or punched out of a normal neoprene or other foam rubber plate, or other soft material. The visor pattern is crushable any random number of times and always returns to its original smooth form without leaving any traces of fold or wrinkle marks. Once the cap is placed on the head, as seen from the top, the central visor range gets a convex curvature, in such a way that the front edge of the visor is curved to an arch form.

[0008] This gives the visor a sufficiently high form stability but it remains pliably elastic so that at impact or hitting against a resistance it can flip up or downwardly without causing any injury to the head of the wearer. This is of essential importance when a sport ball hits the cap. Once the stress impact on the visor ceases, the visor springs back to its arched original position. Especially advantageous for the form stability of the visor is when on both sides of the convex middle curvature section a concave curvature section each is joined. By doing this a double arch of the visor is created which increases the form stability. Both of the lateral concave curvature sections have less of a curvature than the middle convex curvature section and the side edges of the visor run out to the inner edge of the visor almost in a straight line.

[0009] Although the visor as described in the invention can have an especially long length, i.e., stretching out a long distance from the front of the head, it cannot collapse due to its curvature. The sport cap can be crunched together into a very small package-size and put into a trouser pocket for example without leaving any folds or creases when the cap is placed on the head. The form stability of the cap is practically unlimited when on the head. The neoprene foam rubber material also has the advantage of being absolutely water resistant making it especially suitable for all types of outdoor sports.

[0010] The procedure for manufacturing based on the invention description consists of punching or cutting out of a roughly crescent-shaped visor from a neoprene foam rubber plate of at least approximately 3 mm thick (e.g. 1 to 5 mm) and the sewing or other attachment on of the inner edge of the visor to the lower edge of the cap and the bottom edge of the head-band. While sewing the visor, it is especially important that the inner edge, at least in certain spots, is stretched out substantially straight. Although sewing is preferred, the cap parts and/or visor can be attached in other ways such as fusing or gluing.

[0011] The most important thing to bear in mind when sewing the neoprene visor onto the crown of the cap is to maintain the same amount of stretch-tension on both sides of the visor. Failure to do so will result in the visor having a lopsided shaped when the sewing is completed.

[0012] The way to maintain proper proportionality of visor stretch is to first align the center of the visor with the center of the crown, and then, for the sewing attachment process, to stretch the visor approximately 1 inch (e.g. ¼ to 2 inches) from each corner to the center along the visor's inner concave edge, which is sewed on in a straight-stretched form between the edge of the headband and the edge of the crown of the cap (This stretch of 1 inch each way will vary if the size of the cap is significantly larger or smaller, as would be the case with, for example, child sizes). When done properly, the visor on the completed had will assume a nicely curved proportional shape (not enough stretch yields a flat visor and too much yields the over-curvature of an unsightly exaggerated duckbill shape).

[0013] In most production settings, the visor will be attached first to the headband, and this should be done with minimal stretching of either the headband or the visor. The stretching which is described above will occur when the visor (already attached to the headband) is stretched along the edge of the cap crown. It is also conceivable that some manufacturers will be able to stretch the visor and sew it between the headband and the crown in one cost-efficient step. Even here, though, the basic process remains the same.

[0014] The sewing-on procedure may be done in two steps, whereby the sewing should be started in the middle and the first half, up to the end of the inner edge of the visor, is sewn on the head-band and cap. The other half of the inner edge of the visor is sewn on the same way starting from the middle point.

[0015] The cap form is not important for the invention based cap. The cap is preferably made of a number of material segments put together, although this is not absolutely required. The elastic head-band is preferably designed as a closed ring whose circumference can be fitted to individual head sizes. The elastic head-band usually has a loose upper edge and a bottom edge which is sewn to the inner edge of the visor.

[0016] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention is described in detail using drawings in which an example cap is explained.

[0018] In the Drawings:

[0019]FIG. 1 is a view of the new sport cap placed on the head;

[0020]FIG. 2 is a side view of the sport cap;

[0021]FIG. 3 is a front view of the sport cap;

[0022]FIG. 4 is a detail section which has been circled in FIG. 2;

[0023]FIG. 5 is a view of the form the visor takes on when stretching the inner edge of the visor in the head-band area;

[0024]FIG. 6 is a front view of the visor form created when stretching the visor inner edge;

[0025]FIG. 7 is a side view of the visor with stretched visor inner edge; and

[0026]FIG. 8 is an underside view of the cap with stretched visor inner edge.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The sport cap 10 of the invention comprises a crown 12 with inward laid elastic head-band 14 and a visor 16. The visor 16 is made of a crescent-shaped neoprene foam rubber with a thickness of at least 3 mm and has a slightly curved front edge 18, almost straight or slightly convex curved side edges 20 and an arched form transition section 22 between the front edge 18 and the side edge 20. The inner edge of the visor 16 is shown as 24. The length of the visor 16 at its middle width between front edge 18 and inner edge 24 is at least double the length of the side edge 20. The inner edge 24 of the visor 16 is sewn to the lower edge of the cap 12 and the bottom edge 44 of the elastic headband 14, and preferably there between. It should be appreciated that other equivalent methods exist that could be used to attach the inner edge 24 to the lower edge of the cap 12 and the bottom edge 44 of the elastic head-band 14. Band 14 also may be all elastic or elastic for only part of the way around the crown.

[0028] The inner edge 24 of the visor 16 is approximately parabolic in form in flat laid out condition, i.e., the inner edge 24 has its greatest curvature at the vertex and this curvature gradually minimizes as it approaches both ends of the inner edge 24. When sewing the inner edge 24 of the visor 16 to the elastic head-band 14 and preferably to the cap 12 at the same time, the inner edge is stretched out, i.e., pulled substantially straight. The sewing is preferably started in the middle of the inner edge 24 and a first half, up to the end of the inner edge 24 of the visor 16, is sewed on to the elastic head-band 14. Then afterwards, the other half of the inner edge 24 is sewn on the same way starting from the middle point. The same stretching tension is applied to each end of the inner edge 24 of the visor 16 when the inner edge 24 is being sewn onto the elastic head-band 14. In contrast, the elastic head-band 14 is maintain in a tension-free, i.e., non-stretch, state when the inner edge 24 of the visor 16 is sewn thereto.

[0029] The visor 16 takes on the forms as shown in FIGS. 5-8, whereby, as seen from the top, a middle heavy convex arched curvature section 26 and heavy concave arched curvature sections 28 adjacent to each side are created.

[0030] The middle curvature section 26 has a straight lined contour 30 in the side view. (FIG. 7) The stretching out of the inner edge 24, i.e., the straightening of this during sewing on of the visor 16, is essential for the form stability of the visor 16 in its later usage function.

[0031] If the cap is stretched in its longitudinal direction the visor 16 takes on a form of almost simple curvature, i.e., cuts laid parallel to inner edge 24 have contours which can almost be called drop-shaped forms. Cuts laid out perpendicular run almost in a straight line. Slight inward curvatures toward the ends of the side edges 20 exist at the outer edges of the visor 16.

[0032] In the usage position of the cap 10, the visor 16 takes on a form which lies between that of the longitudinal stretch and the cross stretch of the cap. The inner edge 24 is pulled evenly in radial direction, by which the visor 16 gets a middle convex curvature section 32, whose curvature radius is larger than that of the curvature 26 when cross stretching of the inner edge 24. The front edge 18 of the visor in this curvature section 30 has an arch-form with almost constant curvature.

[0033] On both sides of the middle curvature section 32, a slightly concave arched curvature section 34 is joined which in its curvature is much less pronounced than the lateral curvature section 28 in the cross stretched form of the inner edge 24. The curvature sections 32,34 converge completely uniformly into one another. This combination of heavy front convex curvature in connection with a weaker lateral concave curvature leads to an extreme form stability of the visor 16 when the cap is being worn on the head. The form of the visor 16 is renewed each time it is put on and does not lose its form at any time during the duration of usage.

[0034] The pattern of the visor 16 made of neoprene material has a slightly curved front edge 18 and almost straight side edges 20 whereby the visor width measured between the side edges gets somewhat smaller towards the front edge 18. The arched radius of the transition arch 22 is preferably smaller than that of the front edge 18.

[0035] The cap 10 with its visor 16 can be packed tightly together, e.g., rolled, folded, and crushed uncontrollably and can remain in this condition for any amount of time and the visor 16 will still take on its smooth curved form once the cap 10 is placed on the head again. The appearance and the function of the cap remain unchanged.

[0036] While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. 

What is claimed is:
 1. A cap comprising: a crown with a lower edge; a head-band which is at least partly elastic and which has an upper edge and a lower edge; and a visor made of an elastic deformable material, said visor having a curved inner edge in use, said curved inner edge having a pair of opposite ends, said visor being attached to the lower edge of the crown and the lower edge of said head-band when the visor is stretched between the opposite sides thereof.
 2. The cap of claim 1, wherein the visor is attached to the crown by aligning the visor with a front portion of the crown; stretching the opposite outer ends of the curved inner edge of the peak approximate the same distance in opposite directions so that the curved inner edge is made substantially straight; and attaching the substantially straight inner edge to the lower edge of the crown and the lower edge of the headband.
 3. The cap of claim 1, wherein the curved inner edge is attached between the lower edge of the crown and the lower edge of the headband.
 4. The cap of claim 1, wherein each opposite end of the curved inner edge of the visor is stretched approximately ¼ to 2 inches before the visor is attached to the crown.
 5. The cap of claim 1, wherein the crown is comprised of a plurality of panels.
 6. The cap of claim 1, wherein the crown is non-elastic.
 7. The cap of claim 1, wherein the visor has a front edge located opposite the inner edge, and a side edge located between the inner edge and the front edge, wherein a distance between the front edge and the inner edge is at least twice the length of the side edge.
 8. The cap of claim 1, wherein the visor has a thickness of at least 3 mm.
 9. The cap of claim 1, wherein the inner edge of the visor has, at least approximately a parabolic form.
 10. The cap of claim 1, wherein a curvature in a middle range of the inner edge of the visor is greatest and gradually reduces toward the opposite outer ends of the inner edge.
 11. The cap as claimed in claim 1, wherein the visor is elastic deformable neoprene.
 12. A method for assembling a sport cap having a cap with a lower edge, an elastic head-band with a bottom edge, and a peak made of an elastic deformable foam rubber material, said peak having a curved inner edge, said curved inner edge having a pair of opposite ends which are substantially aligned with each other when the peak is in a flat position, said method comprising the following steps: (a) aligning the peak with a front portion of the cap; (b) stretching the opposite ends of the curved inner edge of the peak approximate the same distance in opposite directions so that the curved inner edge is substantially straight; and (c) attaching the substantially straight curved inner edge between the lower edge of the cap and the bottom edge of said elastic head-band, during which the elastic head-band is maintained in a substantially tension-free state.
 13. The method of claim 1, wherein the curved inner edge is attached between the lower edge of the cap and the bottom edge of the elastic head-band.
 14. The method of claim 1, wherein the each opposite end of the curved inner edge of the peak is stretched approximately ¼ to 2 inches during the stretching in step (c)(2).
 15. The method of claim 1, wherein the same amount of tension is applied to each opposite end of the curved inner edge during the stretching in step (c)(2). 